In the ever-evolving spectrum of architecture and construction, the facade has evolved from a mere static structure to a canvas of creativity. The new era facade materials such as Aluminium Composite Panels intertwined design, technology, and functionality to elevate the archaic methods and materials of construction.
With competitive price and timely delivery, Litong sincerely hope to be your supplier and partner.
As Aluminium Composite Panels are lightweight, flexible, easy to install, maintain, and shape, these have emerged as a transformative force, revolutionising the face of modern construction. Utilising it in your property for exterior facades, interior applications, transportation, and furniture facades, the need for quality ACP is paramount. This is where Alumaze comes in. How do we help in elevating the aesthetics, and why you should invest in Alumaze's ACP sheet for your property, are answered here in the blog, so keep reading it!
Alumaze is one of the leading ACP sheet manufacturers in South India, which is pioneering innovation in the ACP sheet industry. The first in India Five Calendar Technology is pushing the ideas forward and ensuring you receive high-quality panels. The five calendar technology consists of hard press rollers that enable consistent smoothness in the entire roll of the ACP sheet. It ensures the evenness of the ACP sheet.
Apart from that, the manufacturing unit at Vizianagaram is spread over an area of 2 acres powered with Conical Twins Screw Extruder technology. The 4 extruder lines are responsible for manufacturing LDPE granules that facilitate the manufacturing of quality ACP Sheets.
Design finishes influence the way we perceive a structure. With the opportunity to experiment with design, it is important the panels support the imagination. ACP sheets are known as the property of imitation, which means the panels can imitate any texture or finish of traditional materials. At Alumaze, we have a range of ACP design series, which has biomimicry in shades, and textures, and some also mimic commonly used construction material such as Marble Series, Sand Series, Mirror Series/Metallic/Glossy Series, Stone Series, Wooden Series and Vintage textures and tones with Antique Series. We utilise 1PE, 2PE, and PVDF coating to add various finishes and textures to the sheets.
The cladding material is susceptible to damage from UV rays, rain, and corrosion. But when ACP sheets are put to the test, they shine through the test of time! To incorporate this feature into our ACP panel, we have engineered top-grade aluminium and quality polyethylene core, which ensures strength and durability of the panels. Alumaze's ACP sheets are built to resist weather elements, corrosion, and wear, ensuring your property remains aesthetically appealing for years to come.
The ability to withstand fire and retard helps in enhancing the structure strength of your property. The core of Alumaze's fire retardant sheets contains fire-resistant adhesive, that reduces firer propagation into the core and helps in achieving fire safety guidelines for your building.
Moreover, the toxin-free adhesive does not produce any toxic gases or vapour during a fire breakout, which eases the evacuation process. This is crucial as it makes evacuating the premises easier during such emergencies. Additionally, the panels are designed to cause minimal harm to the building's structure, providing valuable time to take the required measures to fully extinguish the fire.
The primary application of ACP sheets is to be used as wall panelling, signage, and false ceilings. These are mostly exterior applications which are exposed to rain and moisture in the air. The contact of moisture in the air with Aluminium can lead to corrosion, hence weakening the structural integrity. This is why, we add DuPoint Adhesive film, along with a protective film above the PVDF coating to resist damage due to moisture. This enures the sheet remains unaffected by moisture and enhances the lifespan. Being anti-corrosive, these sheets does not allow water to penetrate or settle on the panels that prevents formation of mold into the wall.
Today future of construction and facades is beyond imagination. With structures like 'The Museum of Future' at Dubai, Mediopadana Station at the province of Reggio Emilia is what the construction of tomorrow might look like. To facilitate such construction, a visionary architect need right facade material which is highly customisable and flexible. With our high-tech manufacturing unit, we provide 100% customisation making your dreams into our reality. Be it customisation in textures, finishes, or even dimensions of the panels, we do not limit ourselves, helping our clients to get the result they want from ACP sheets.
One of the features of aluminium composite panels that makes it stand out among other new-age materials such as glass, or fibre, is flexibility. The panels are 90-degree flexible, which allows architects to experiment with different structures and methods of installation. At Alumaze, we test the hardness of the panels, to ensure it is flexible enough to be shaped in a range of designs, yet sturdy enough to resist damage and breaking of panels.
In interiors, ACP cladding is used as roofing, wall panelling, and furniture cladding. The thin sheets of 3mm width are perfect for elevating the designs and creating statement walls at cost constraint budget.
The beauty of any property comes from its exterior, ACP sheets are able to withstand changes in temperature, weather, and fire, making it the right material for building elevation.
ACP sheets are perfect for corporate branding, as the panels can imitate the texture and finish of branded hues. These panels are preferably a better choice over vinyl and traditional signage.
Choosing Alumaze's Aluminium Composite Panels for your property equips you with a high-quality, versatile, and aesthetically appealing solution. With a focus on quality, sustainability, and customer satisfaction, Alumaze stands as a reliable partner for enhancing the look and durability of your property with Aluminium Composite Panels.
The following is the third and final part in a series of 3 blogs that has gone through a white paper written by New Era Converting Machinery's John A. Pasquale III. The white paper is titled 'Principles and Uses of Roll Coating Equipment.'
Part 1 offered an abstract and introduction to the blog series, as well as an in depth look at direct gravure coating. Part 2 examined both reverse gravure coating and differential offset gravure coating. Part 3 will wrap the series up with an explanation of reverse roll coating and offer a brief conclusion.
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Reverse Roll Coating
For purposes of this presentation, a nip fed Reverse Roll Coater, as shown in Figure 7, will be used. It is considered the most versatile for applying precise coatings of varying viscosity and thickness, particularly on webs that do not have uniform caliper (thickness). Reverse roll coating takes advantage of gap control, supplemented by differential speed control of the applicator and metering rolls, causing the coating to be precisely metered before being applied to the web. Each roll is independently driven.
In a Reverse Roll Coater, the substrate is carried on a resilient, rubber covered carrier roll, operating at line speed. Two steel precision rolls, one an applicator roll and the other a metering roll, are gapped to each other to help determine the coating thickness applied to the web. The steel rolls are high precision, with tolerances to 1.25 microns for concentricity and total indicator run out. The roll surface is chrome covered, with a finish in the 0.05- 0.20 μm range. Coating is fed into the gap of these steel rolls, contained by a trough and edge dam system. The applicator roll normally operates at speeds from 1.2 to 2.5 times faster than web speed, thereby depositing a greater amount of coating for a given gap between the metering and applicator rolls. The ratio of the speed of the metering roll to the applicator roll can be an important factor in determining the surface quality of the coating applied to the web. It also has some effect on the thickness of the coating.
The coating is precisely premetered onto the surface of the applicator roll by the gap setting and the action of the metering roll speed. Since both rolls are steel, they do not deform, as does an elastomer rubber covered roll. Hence, for a given gap, the flow parameters of the coating (capillary number, surface tension) and the speed of metering to applicator rolls determines the coating thickness.
For coatings that exhibit increased resistance to shear (Newtonian coatings), the ratio of metering to applicator roll speed will affect the quantity of the coating ultimately applied to the applicator roll. If the speed of the metering roll is too low, 'ribbing' (machine direction lines) will occur. It is usually caused by air becoming entrained on the metering roll, resulting in competition between coating flow pressure at the nip and the cross-machine coating flow properties. The smaller the coating gap, the higher the frequency of the 'ribbing'. Increasing the metering roll speed will stabilize the coating on the applicator roll. If the ribs remain, you may have to increase the coating gap.
If, however, the speed of the metering roll is too high, 'cascading' (seashoring) will occur. 'Cascading' takes place when the dynamic contact line of the coating, normally located downstream of the gap, passes from the downstream side to the upstream side of the gap, entrapping air in the roll gap. This results in an increase in coating film thickness upstream due to surging. It is therefore important to find the combination of metering to applicator roll gap and speed that allows coating in the stable range. The flow properties of the coating (capillary number,surface tension) become less of a factor as proper speed ratio and coating gap are established. However, when applying coatings that exhibit a narrow stable operating range, gap control becomes extremely important. The ability to process a wide range of different coatings makes the Reverse Roll Coater very popular.
For shear-thinning (thixotropic) coatings, there is very little change in the metered film thickness as a function of metering roll speed. This is due to relatively low capillary number and surface tension values of this family of coatings. The viscosity of the coating is important, however, and is defined as the process shear rate developed in the area of the gap where the shear-thinning takes place.
As in all coating processes, the doctoring of excess material carried around the metering and applicator rolls is imperative. The use of composite material doctor blades, acting in the 'chisel' (roll turns into the edge of the blade, shearing off the coating) mode is typical in most applications. This helps minimize coating carryover due to the hydrodynamics of the coating against a doctor blade operating in the 'trail' (roll turns against the edge of blade, wiping off coating) mode.
The gap between the metering and applicator rolls is controlled by a precision wedge block or rotary screw system. While adjustment of the control units may be performed manually, most devices use servomotor controls to ensure accurate, repeatable settings. Weight and thickness measuring gauges that monitor the coating application can send a signal through their microprocessor, activating the gap set control motors to make a corrective adjustment. The gap adjustment system between the applicator rolls and carrier rolls is primarily a manually adjustable device whose action controls the transfer force used when depositing the coating onto the moving web.
While the cost of a Reverse Roll Coater is higher than other roll coaters, it offers the greatest flexibility for processing a wide range of coatings in a precise manner.
CONCLUSIONS
There is no universally superior coating method, only the best type for a given application. By knowing the substrates to be coated, coating properties, coat weight/thickness requirements and accuracy expected, you can select the best coating technique to manufacture your product. Once the type of coater has been established, select control and component features appropriate for that coater.
ACKNOWLEDGEMENTS
I wish to thank my fellow employees for their input and support in the development of this paper.
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*That concludes our 3 part blog series, 'Principles and Uses of Roll Coating Equipment' ' thanks for reading! If you missed them, go back and read part 1 and part 2!*
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